Crown molding system

ABSTRACT

A crown molding system includes first and second crown molding members, first and second brackets for attachment to a room wall or ceiling, and a bridge piece for connecting the first and second crown molding members. Each of the first and second crown molding members includes an attachment portion for mating attachment with the respective first or second bracket, and the bridge piece includes upper and lower tabs engageable with the first and second crown molding members to span a gap between the first and second crown molding members.

FIELD OF THE INVENTION

The present invention relates to crown molding systems and more particularly to a modular crown molding system for installation at a ceiling-wall juncture of a room.

BACKGROUND

Crown molding is a desirable addition to a room to complete a finished look to the wall- ceiling juncture. However, traditional wood crown molding can be difficult to install due to the precise dimensions and alignment that are needed in order to properly fit the wood molding pieces to a room. Installation of traditional wood crown molding often requires a professional carpenter, and if not done properly, can leave gaps and spaces between the molding, ceiling, and wall.

Even when materials other than wood are used to install crown molding, such as extruded plastic pieces attached to the room wall or ceiling, there still remains a problem in aligning these pieces with each other to prevent gaps between molding sections. Additionally, precise measurements and precise cuts are often needed in order to install inside and outside corner pieces. As a result, there is still a need for a user-friendly crown molding system that can be easily installed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a rear perspective view of a crown molding system according to an embodiment of the invention.

FIG. 2 shows a side cross-sectional view of a crown molding system installed at a wall-ceiling juncture of a room, according to an embodiment of the invention.

FIG. 3 shows a perspective view of a bridge piece according to an embodiment of the invention.

FIG. 4 shows an exploded view of a crown molding system with a bridge piece connecting two molding members, according to an embodiment of the invention.

FIG. 5 shows an outside corner piece according to an embodiment of the invention.

FIG. 6 shows an inside corner according to an embodiment of the invention.

FIG. 7 shows a front view of a crown molding system according to an embodiment of the invention.

DETAILED DESCRIPTION

The present invention relates to crown molding systems and more particularly to a modular crown molding system for installation at a ceiling-wall juncture of a room. In one embodiment, a crown molding system includes a bracket that is attached to a room wall at the ceiling, and a facing crown molding member that engages the bracket. The brackets are attached to a room wall at the juncture with the ceiling, such as by nailing, screwing, adhering, or otherwise fastening the brackets to the wall. The facing crown molding member can then be easily snapped into engagement with the brackets. The crown molding system further includes bridge pieces that clip to the molding members to connect the molding members end-to-end and to cover any gaps resulting from imprecise measurements or cuts. In a further embodiment, the crown molding system includes an outside corner piece that can be easily clipped to two molding members, and two mating inside corner pieces that overlap to cover any excess length. The crown molding system can be installed in a room without leaving gaps or spaces where molding pieces are not precisely cut to exact room dimensions.

A crown molding system 10 is shown in FIGS. 1-2. The crown molding system includes a facing molding member 12 and a rear L-bracket 14. The L-bracket 14 is attached to a wall of a room at the juncture with the room ceiling. The L-bracket can be attached to the wall in any suitable way. In one embodiment, the L-bracket includes a hole 16 for a nail 18 or a screw or other fastener, and the bracket is held in place against the wall by the nail (see FIG. 2). In another embodiment, the L-bracket may be glued or adhered to the wall. The L-bracket does not extend along the length of the molding, but instead has a shorter length L1 (see FIG. 1). Several brackets 14 are attached to the room wall at spaced intervals.

The facing molding member 12 has a curved outer face 20 that faces into the room and presents the desired decorative appearance. The outer face 20 can have any of a variety of different styles, shapes, and curves depending on the user's preference. In one embodiment, the facing molding member 12 is made from an extruded polymer, such as polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS). The molding 12 has a uniform cross-section along its length. The L-bracket 14 may also be extruded and then cut to the shorter length L 1.

The facing molding member 12 engages the L-bracket to attach the molding to the room wall. The molding 12 and bracket 14 include mating mechanical features that engage to hold the two pieces together. In one embodiment, the L-bracket includes a lower leg 22 that extends along the room wall, and an upper leg 24 that extends along the room ceiling. The upper leg 24 includes a connector portion 26 at its front end. The connector portion 26 includes one or more recesses 28 formed in the upper surface of the upper leg, facing the ceiling. In one embodiment, the recesses 28 are formed as grooves or corrugations in the upper leg. In other embodiments, the recesses can have other shapes, such as bowl-shaped depressions, or other types of indentations. The recesses may also be formed as spaces between raised portions of the upper leg 24. In either case, the hook and stub provide a C-channel that is integrated into the bracket.

The molding 12 also includes a mating connector portion 30. In one embodiment, the mating connector portion 30 includes an upper flange 32 extending rearwardly behind the outer face 20 of the molding. The upper flange 32 includes one or more protrusions 34 on the lower surface of the flange. These protrusions 34 are shaped and sized to mate with the recesses 28 in the upper leg 24 of the L-bracket 14. In one embodiment, the protrusions include mating corrugations or ridges that are received into the corrugations or grooves of the connector portion 28 of the L-bracket. In other embodiments, the protrusions 34 and recesses 28 can have other mating geometries.

To attach the molding member 12 to the L-bracket 14, the molding member is positioned in front of the bracket and then pushed inwardly toward the wall, so that the protrusion(s) 34 are received into the recess(es) 28. In one embodiment, the L-bracket includes a ramp 36 at the forward end of the upper leg 24, to guide the upper flange 32 of the molding member over the upper leg and into the recess(es). The two connector portions 26, 30 mate together to secure the molding to the bracket. The molding can be similarly removed from the bracket by gripping it and pulling it out of the recess(es) 28 to free it from the bracket.

In one embodiment, the molding 12 includes a ridge 38 at the intersection of the outer face 20 and the upper flange 32. The ridge 38 extends upwardly above the upper surface of the flange 32. As shown in FIG. 2, the ridge 38 contacts the room ceiling. The upper leg 24 of the L-bracket is resilient and flexible to bend downwardly to accept the upper flange 32 into the connector portion 26. The upper leg 24 urges back upwardly against the upper flange 32 and pushes it toward the ceiling. This action pivots the molding 12 about the ridge 38, forcing the molding 12 into tight contact against the ceiling and the wall.

At the lower end of the molding 12, the outer face 20 curves inwardly to form a foot 40 that extends toward the room wall. A lower flange 42 connects to the foot 40. At the intersection of the foot 40 and the lower flange 42 is another ridge 44 which contacts the room wall. The two ridges 38, 44 provide a clean line of contact for the molding 12 against the room ceiling and wall.

When the molding 12 is engaged with the bracket 14, the bracket is no longer visible, and is hidden behind the outer face 20 of the molding. The bracket 14 may also be used to run cables and wires behind the outer face 20 of the molding. In one embodiment, the bracket 14 includes a C-channel 50 on either the upper leg 24 or the lower leg 22. In FIGS. 1-2, the C-channel 50 is formed on the lower leg 22. The lower leg 22 includes a hook 52 at its bottom end, which curls inwardly from the wall. The bracket also includes a rim or stub 54 that projects downwardly from the upper leg 24. The hook 52 and stub 54 together form opposite ends of the C-channel 50. A clip can be inserted into the C-channel 50 and then rotated 90 degrees to engage the hook 52 and stub 54, to secure the clip in the C-channel. Electrical wires, cables, and other components can then be connected to these clips and run along the molding behind the molding member 12, so that the wiring is not visible from the room. Although the C-channel is show in FIGS. 1 and 2 on the lower leg 22, along the wall, it could also or alternatively be provided on the upper leg 24, along the ceiling.

When installing the crown molding system into a room, the room wall will often be loner than a single section of molding 12. As a result, two or more sections of molding 12 are snapped into place into the L-brackets 14 spaced along the room wall. Depending on the length of the room wall, one or more sections of the molding 12 may need to be cut to fit the geometry of the room. As the user is measuring the room and installing the molding 12, he or she may make a measurement error or may make an imprecise cut across a crown molding section 12. This may result in a gap between two molding pieces 12 that are installed end-to-end in the room. The user may also make a rough, slanted, or curved cut that does not match with the straight end of the adjacent molding section 12.

According to an embodiment of the invention, a bridge piece 60 is provided to span such a gap, as shown in FIGS. 3-4 and 7. The bridge piece 60 includes an outer face 62 that matches the curve and shape of the molding member 12, including a foot 40. However, the bridge piece 60 is designed to clip directly to two molding member 12, rather than to an L-bracket 14. Therefore, the upper flange 32 and the lower flange 42 are both absent. Instead, the bridge piece 60 includes two tabs 64 at the upper end of the piece. The tabs 64 each include a prong 66 pointing downwardly from the lower surface of the tab 64. Two foot tabs 68 are also provided, extending upwardly from the inside, upper surface of the foot 40. The foot tabs 68 each have a tapered shape, narrowing toward the top.

To install the bridge piece 60 to the crown molding system, the piece is snapped over the front of the two adjacent molding members 12, as shown for example in FIG. 4. In FIG. 4, a first molding member 12A is shown with the bridge piece 60 attached, and a second molding member 12B is shown in an exploded view. In a room installation, the gap between the two molding members 12A, 12B should be small enough to be contained within the span of the bridge piece.

To attach the bridge piece, first the foot tabs 68 are inserted behind the molding members 12A, 12B, between the moldings and the wall. The tapered shape of the tabs 68 allows the tabs to slide in between the moldings and the wall, over the lower ridge 44. Then, the two upper tabs 64 are snapped over the ridge 38 along the molding members 12A, 12B. The prong 66 of the tab 64 snaps over the ridge 38 and grips the molding, with the ridge 38 trapped firmly between the prong 66 and the bridge piece. One tab 64 is snapped over the top ridge 38 of the first molding 12A, and the other tab 64 is snapped over the top ridge 38 of the second molding 12B. The bridge piece 62 then spans the gap between the two molding sections. A finished bridge piece 60 clipped between two moldings 12A, 12B is shown in FIG. 7.

The bridge piece 60 covers gaps between molding pieces, in case the moldings are cut imprecisely or erroneously. The bridge piece 60 also covers the edges 13 of the molding pieces, hiding any rough surfaces or slanted edges 13. This bridge piece provides a buffer for the user so that the user does not have to create very precise, straight cuts of the molding members 12A, 12B. In one embodiment, the bridge piece 60 has a keystone shape, having a wider span W1 at its top end and a narrower span W2 at its lower end. This shape creates a decorative keystone-type shape at the break in the molding sections, rather than an imprecise seam or gap.

An outside corner piece 70 according to an embodiment is shown in FIG. 5. The outside corner piece is designed to fit around an outside corner in a room, to connect two molding sections 12 on each side of the corner. Similar to the bridge piece 60, the outside corner piece 70 includes tabs 64 with prongs 66, and foot tabs 68. The prongs 66 of the tabs 64 fit over the upper ridge 38 of the two molding sections on each side of the outside corner. The foot tabs 68 slide into place between the lower ridge 44 and the wall. The edges (see edge 13 in FIG. 4) of the molding sections are hidden behind the outside corner piece. The molding sections can end anywhere within the length L2 of the outside corner piece 70. This length L2 accommodates and hides imprecise or rough cuts along the edges of the molding sections.

An inside corner 72 according to an embodiment of the invention is shown in FIG. 6. The inside corner is made up of a forward corner piece 74 and a rear corner piece 76. Each corner piece has an outside face 78 with a decorative curved pattern that matches the outer face 20 of the molding sections 12. The forward corner piece 74 includes an edge 75 that fits along the outer face 78 of the rear corner piece 76. The edge 75 may be known as a coping cut, following the profile of the outer face 78. The remaining length L3 of the rear corner piece 76 extends behind the forward corner piece. That is, the forward corner piece overlaps the rear corner piece and hides the end 79 of the rear corner piece from view. This overlapping design allows the rear corner piece to have extra length, rather than requiring a precise cut that aligns with the edge 75 of the forward corner piece 74. In another embodiment, the rear corner piece 76 is not a separate piece, but instead is the end of a molding section extending along the wall toward the room corner. However, using two corner pieces may be preferable for aesthetic reasons to provide a symmetric matching corner.

The two corner pieces each have upper tabs 64 with prongs 66, and foot tabs 68. These operate to engage the molding sections 12 as described earlier.

The various connector pieces described herein, including the inside and outside corner pieces and the keystone pieces, may be formed by injection molding.

Embodiments of the molding system described herein provide a finished crown molding along a wall-ceiling juncture that can accommodate imprecisions in measurements and cuts to the crown molding pieces. The gaps and seams between pieces can be covered by the bridge and corner pieces to provide a polished final appearance. If desired, caulking can be added to the crown molding where it contacts the wall and the ceiling. Installation of this system can be done easily by attaching brackets at spaced intervals along the wall, measuring and cutting crown molding sections 12 according to the room length, snap-fitting the moldings into the brackets, and providing corner and bridge pieces as necessary to finish the crown molding system. Additionally, the crown molding system can be easily removed from the room if desired.

Although the present invention has been described and illustrated in respect to exemplary embodiments, it is to be understood that it is not to be so limited, since changes and modifications may be made therein which are within the full intended scope of this invention as hereinafter claimed. 

What is claimed is:
 1. A crown molding system comprising: first and second crown molding members; first and second brackets for attachment to a room wall or ceiling; and a bridge piece for connecting the first and second crown molding members, wherein each of the first and second crown molding members comprises an attachment portion for mating attachment with the respective first or second bracket, and wherein the bridge piece comprises upper and lower tabs engageable with the first and second crown molding members to span a gap between the first and second crown molding members.
 2. The crown molding system of claim 1, wherein the bridge piece comprises a tapered shape.
 3. The crown molding system of claim 1, further comprises an outside corner piece having upper and lower tabs for engagement with such crown molding members.
 4. The crown molding system of claim 1, further comprising an inside corner that comprises a forward corner piece overlapping a rear corner piece, wherein each corner piece comprises upper and lower tabs for engagement with such crown molding members.
 5. The crown molding system of claim 1, wherein the upper tab of the bridge piece comprises a downwardly facing prong.
 6. The crown molding system of claim 5, wherein the prong engages an upwardly facing ridge on the first and second crown molding members.
 7. The crown molding system of claim 5, wherein the lower tab of the bridge piece is tapered, and wherein the lower tab engages a foot of the crown molding members. 